Method and system for improved curtain wall sealing

Abstract

In one aspect, the present invention relates to a plug of the type utilized for sealing a junction between a horizontal member and a vertical mullion of a curtain wall. The plug may include a plug body. The plug body may include a front body portion, a rear body portion, a left body portion, a right body portion, a top surface disposed between the left body portion, the right body portion, the front body portion, and the rear body portion. A rabbet is disposed across the front body portion. A spacer flange extends from the front body portion. A plurality of chamfers are disposed between the top surface and the left body portion, the right body portion, and the rear body portions. The plug is sized to occupy a gap formed in the junction between the horizontal member and the vertical mullion of the curtain wall. The rabbet and the plurality of chamfers form a plurality of large crevices between the plug, the horizontal member, and the vertical mullion. The large crevices allow penetration of a sealant therein.

What is claimed is: 
     
       1. A plug for sealing a junction between a horizontal member and a vertical mullion of a curtain wall, the plug comprising:
 a plug body comprising:
 a front body portion; 
 a rear body portion; 
 a left body portion; 
 a right body portion; and 
 a top surface disposed between the left body portion, the right body portion, the front body portion, and the rear body portion, the top surface being sloped from the rear body portion downwardly towards the front body portion; 
 
 a rabbet disposed across the front body portion; 
 a spacer flange disposed above and extending from the front body portion, the spacer flange having a long axis that extends in a direction that is generally perpendicular to the front body portion; 
 a first chamfer formed at a junction between the top surface and the left body portion; 
 a second chamber formed at a junction between the top surface and the right body portion; 
 a third chamfer formed at a junction between the top surface and the rear body portion;
 wherein, the plug is sized to occupy a gap formed in the junction between the horizontal member and the vertical mullion of the curtain wall; 
 
 wherein, the rabbet, the first chamfer, the second chamfer, and the third chamfer form a plurality of crevices between the plug, the horizontal member, and the vertical mullion; and 
 wherein the crevices allow penetration of a sealant therein. 
 
     
     
       2. The plug of  claim 1 , wherein the gap is formed in the horizontal member. 
     
     
       3. The plug of  claim 2 , wherein the spacer flange engages a cut end of the horizontal member. 
     
     
       4. The plug of  claim 1 , wherein the gap is formed in the vertical mullion. 
     
     
       5. The plug of  claim 4 , wherein the spacer flange engages a cut end of the vertical mullion. 
     
     
       6. The plug of  claim 1 , wherein the top surface is contoured to match a surface contour of at least one of the horizontal member and the vertical mullion. 
     
     
       7. The plug of  claim 1 , wherein the top surface is sloped towards the front body portion. 
     
     
       8. The plug of  claim 1 , wherein the plug body is rectangular shaped. 
     
     
       9. The plug of  claim 1 , wherein the spacer flange is oriented generally orthogonal to the front body portion. 
     
     
       10. The plug of  claim 1 , wherein the spacer flange aligns the plug in the gap. 
     
     
       11. The plug of  claim 1 , wherein:
 the first chamfer is formed at an approximate 45 degree angle relative to the left body portion and the top surface; 
 the second chamfer is formed at an approximate 45 degree angle relative to the right body portion and the top surface; and 
 the third chamfer is formed at an approximate 45 degree angle relative to the rear body portion and the top surface.